AVCENTER, INC.

Operated by Avcenter Inc. (per NTSB report)

Operated by Avcenter Inc. (per NTSB report)

Operated by AvCenter Inc. (per NTSB report)

AFTER DEPARTURE AND DURING THE CLIMB OUT, N284CP EXPERIENCED MULTIPLE AMBER MAINTENANCE MESSAGES THAT INCLUDED #1/2 RUDDER SYS INOP, AUTOPILOT INOP AND PITCH TRIM INOPERATIVE. THE CREW HELD ALTITUDE AT 16,000FT TO PERFORM THE STEPS IN THE QRH TO CLEAR THE MESSAGES. THE CREW WAS ABLE TO CLEAR THE MESSAGES AND MADE THE DECISION TO RETURN THE AIRCRAFT TO IAH FOR MAINTENANCE SUPPORT.

LEFT MAIN LANDING GEAR DRAG BRACE ASSEMBLY P/N EA1570-501 WAS FOUND CRACKED IN THE UPPER PORTION OF THE DRAG BRACE. CRACK WAS FOUND DURING A PRE FLIGHT INSPECTION. THE CRACK IS IN AN AERA THAT TWIN COMMANDER SL 376 ADDRESSES FOR NDT INSPECTION. CRACKED DRAG BRACE HAD 41.9 HOURS SINCE LAST NDT INSPECTION, INSPECTION WAS COMPLETED IN ACCORDANCE WITH TWIN COMMANDER SL376.

ELEVATOR LEFT MIDDLE CONTROL CABLE FREQUENTLY WEARS BEYOND MANUFACTURER'S LIMITS WHERE THE CONTROL CABLE PASSES THROUGH A FAIRLEAD LOCATED ROUGHLY AT FS 415. PROPER FLIGHT CONTROL RIGGING HAS BEEN VERIFIED SEVERAL TIMES. CONTACT WITH THE MANUFACTURER HAS BEEN MADE WITH NO APPROVED REPAIR OR ALTERATION FOR THIS ISSUE ASIDE FROM REPLACING CABLE AS NEEDED. THIS CABLE HAS BEEN REPLACED 3 TIMES ON THIS AIRCRAFT IN THE LAST 1500 HOURS.

FOUND AFT RUDDER TRIM CABLE EXCESSIVELY WORN DUE TO RUBBING ON FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 2400 HOURS AGO DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND LEFT FORWARD PRIMARY RUDDER CABLE EXCESSIVELY WORN DUE TO RUBBING ON ITS' GUIDE TUBE AND FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 2400 HOURS AGO DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND RIGHT FORWARD PRIMARY RUDDER CABLE EXCESSIVELY WORN DUE TO RUBBING ON ITS' GUIDE TUBE AND FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 2400 HOURS AGO DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND LEFT FORWARD SECONDARY RUDDER CABLE EXCESSIVELY WORN DUE TO RUBBING ON ITS' GUIDE TUBE AND FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 2400 HOURS AGO DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND RIGHT FORWARD SECONDARY RUDDER CABLE EXCESSIVELY WORN DUE TO RUBBING ON ITS' GUIDE TUBE AND FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 2400 HOURS AGO DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

PILOT REPORTED ON CLIMB JUST PRIOR TO LEVEL OFF HE SAW AN AMBER RA INOP ON THE PILOT PFD FOLLOWED BY PT TRIM AND AMBER INOP AP RED FAIL. THE RIGHT PFD WENT BLANK FOLLOWED BY THE MFD AND THE THE PILOT PFD. (AIRCRAFT IS EQUIPPED WITH A GARMIN G1000). TURNED ALL LIGHTS OFF, HOT 5 ITEMS. LOOKED AND SAW THERE WERE NO AMPS AND NO BATTERY VOLTAGE INDICATION, NO RADIOS, AND THAT THEY HAD A COMPLETE ELECTRIC SYSTEM FAILURE. PILOT PERFORMED AN EMERGENCY GEAR EXTENSION PRIOR TO LANDING BUT HAD NO WAY OF INDICATING THE GEAR WAS DOWN AND LOCKED DUE TO NO ELECTRIC SYSTEM. UPON LANDING, ALL THREE LANDING GEAR COLLAPSED. THE CAUSE OF THE COMPLETE ELECTRIC SYSTEM FAILURE IS UNDETERMINED AT THIS TIME AND PENDING INVESTIGATION.

NOSE GEAR DID NOT INDICATE UP AND LOCKED AFTER GEAR UP WAS SELECTED. FOUND UPLOCK SWITCH NEEDING ADJUSTMENT. ADJUSTED SWITCH AND OPS CHECKED NORMAL.

FOUND LEFT WING AILERON FORWARD CONTROL CABLE EXCESSIVELY WORN DUE TO RUBBING ON FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 1848 HOURS AGO AND 1405 HOURS PRIOR TO THAT DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND RIGHT WING AILERON FORWARD CONTROL CABLE EXCESSIVELY WORN DUE TO RUBBING ON FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 1848 HOURS AGO AND 1405 HOURS PRIOR TO THAT DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND RIGHT WING AILERON INTERCONNECT CONTROL CABLE EXCESSIVELY WORN DUE TO RUBBING ON FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 1848 HOURS AGO AND 1405 HOURS PRIOR TO THAT DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

FOUND LEFT WING AILERON INTERCONNECT CONTROL CABLE EXCESSIVELY WORN DUE TO RUBBING ON FAIRLEADS THROUGHOUT AIRCRAFT. VERIFIED PROPER CABLE ROUTING AND RIGGING. CABLE WAS REPLACED 1848 HOURS AGO AND 1405 HOURS PRIOR TO THAT DUE TO SAME ISSUE. CONTACTED MANUFACTURER AND DETERMINED THERE IS NO APPROVED REPAIR OR ALTERATION TO FIX THIS ISSUE OTHER THAN REPLACING CABLE. REPLACED CABLE AGAIN AND PROPERLY RIGGED.

RIGHT FUEL CAP LEAKED DURING TAKEOFF ROLL DUE TO LOOSE TENSION.

PRELIMINARY INSPECTION OF ENGINE EXHAUST DUCT SHOWS SIGNS OF SOME TYPE OF FAILURE THAT CAUSED METAL DEBRIS TO ACCUMULATE IN THE DUCT. IT IS SUSPECTED TO HAVE BEEN A BEARING FAILURE AT THIS TIME.

LANDING GEAR FAILED TO EXTEND AFTER GEAR WAS SELECTED TO THE DOWN POSITION.

DURING A SCHEDULED PHASE INSPECTION P/N 100-920041-15 ALUMINUM MAIN FUEL LINE WAS FOUND CHAFED IN THE LT MAIN LANDING GEAR WHEEL WELL WHERE IT ENTERS INTO THE BACK OF THE WING. THE EDGES OF THE HOLE THAT THE LINE PASSES THROUGH WAS PROTECTED WITH PLASTIC ANTI CHAFE MATERIAL THAT WE CALL TANK TRACKS, OR RAILROAD TRACK, AND HAS A PN MS21266-1N. THIS ANTI CHAFE MATERIAL WAS INSTALLED AT THE FACTORY. THIS ANTI CHAFE MATERIAL CAUSED P/N 100-920041-15 ALUMINUM MAIN FUEL LINE TO BE CHAFED ALMOST THROUGH ITS .030 INCH SIDEWALL THICKNESS. THERE ARE OTHER AC THAT HAVE CHAFED FUEL LINES DUE TO THE CLOSE TOLERANCE OF THE FUEL LINES PASSING THROUGH THE STRUCTURE IN THE MAIN LANDING GEAR WHEEL AREA.

PILOT REPORTED THE AIRCRAFT''S PITOT HEAT SYSTEM TO BE INOPERATIVE. INSPECTION REVEALED THE SWITCH ASSY TO HAVE CORROSION IN THE CONTACTS. THE CORROSION APPEARED TO BE CAUSED BY MOISTURE SUCH AS RAINWATER. (X)

LOCKHEED JETSTAR COCKPIT LT REAR SIDE WINDOW (IPC 2-232 FIG 23 ITEM D). WHEN A DEFECT ON LT COCKPIT DV WINDOW WAS INVESTIGATED, FOUND LT REAR COCKPIT SIDE WINDOW, REAR UPPER AND LOWER WINDOW RETAINERS HAD NOT BEEN BOLTED TO WINDOW SUPPORT STRUCTURE. RETAINERS WERE ONLY ATTACHED TO FUSELAGE OUTER SKIN. OVER 30 ATTACHMENT BOLTS ARE MISSING AND LOWER RETAINER IS NOW MISALIGNED BY APPROX .1875 INCH OUTBOARD. VISUAL AND NDT INSPECTIONS ARE BEING CARRIED OUT ON WINDOW AREA OF FUSELAGE. LOCKHEED HAS BEEN INFORMED AND ARE INVESTIGATING REPAIR REQUIREMENTS. ON REAR RT COCKPIT WINDOW, 2 ATTACHMENT BOLTS WERE FOUND MISSING FROM TOP RETAINER.